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Abstract:

Solid detergent compositions according to the present invention include
at least one alkali metal silicate, at least one polycarboxylic acid, at
least one saccharide or sugar alcohol and water. Suitable saccharides
include sucrose, fructose, inulin, maltose and lactulose, and may be
present in the composition in a concentration of at least 0.5 wt %.
Compositions according to certain embodiments form stable solid block
detergent compositions that do not swell significantly even when
subjected to elevated temperatures.

Claims:

1. A solid detergent composition comprising: from about 0.1 wt % to about
70 wt % of at least one alkali metal silicate; from about 0.5 wt % to
about 10 wt % of at least one saccharide or sugar alcohol; and from about
10 wt % to about 70 wt % water.

2. The composition of claim 1, wherein the at least one saccharide
comprises a mono-, di- or polysaccharide comprising three or more
saccharide units.

6. The solid detergent composition of claim 1, and further comprising:
from about 1 wt % to about 15 wt % of at least one polycarboxylic acid.

7. The composition of claim 6, wherein the polycarboxylic acid comprises
at least one maleic acid polymer, at least one acrylic acid polymer or
combinations thereof

8. The composition of claim 1 consisting essentially of the at least one
alkali metal silicate, the at least one saccharide or sugar alcohol,
water and optionally at least one polycarboxylic acid, wherein if the
composition is heated at a temperature of 120 degrees Fahrenheit, the
solid detergent composition is dimensionally stable and has a growth
exponent of less than 2%.

9. The composition of claim 1 consisting essentially of the at least one
alkali metal silicate, the at least one saccharide or sugar alcohol,
water, sodium carbonate, and optionally at least one polycarboxylic acid,
wherein if the composition is heated at a temperature of 120 degrees
Fahrenheit, the solid detergent composition is dimensionally stable and
has a growth exponent of less than 2%.

10. The composition of claim 1, wherein the composition is free of
phosphorous.

11. The composition of claim 1, wherein the at least one alkali metal
silicate is present in an amount between about 25% and about 60% by
weight.

12. The composition of claim 1, further comprising sodium carbonate,
wherein the alkali metal silicate is present in a greater amount than the
sodium carbonate.

13. The composition of claim 1, further comprising from about 15 wt % to
about 40 wt % of sodium carbonate.

14. A method of forming a solid detergent composition, the method
comprising: combining at least one alkali metal silicate, at least one
saccharide or sugar alcohol, and water to form a mixture; and forming a
solid detergent composition from the mixture.

15. The method of claim 14, further comprising the step of forming the
solid detergent composition into a block, capsule, pellet or tablet.

16. The method of claim 14, wherein the step of combining to form a
mixture comprises combining at least one alkali metal silicate, at least
one saccharide or sugar alcohol, at least one polycarboxylic acid, and
water to form a mixture.

17. The method of claim 14, wherein the step of combining to form a
mixture comprises combining at least one alkali metal silicate, at least
one saccharide or sugar alcohol, at least one polycarboxylic acid, water,
and sodium carbonate to form a mixture.

18. The method of claim 14, wherein the at least one saccharide comprises
a mono-, di- or polysaccharide comprising three or more saccharide units.

19. The method of claim 14, wherein the at least one alkali metal
silicate is present in an amount between about 0.1% and about 70% by
weight.

20. The method of claim 14, wherein the at least one saccharide or sugar
alcohol is present in an amount between about 0.5% and about 10% by
weight.

21. The method of claim 14, wherein the at least one polycarboxylic acid
is present in an amount between about 1% and about 15% by weight.

22. A method of cleaning a substrate, the method comprising: mixing water
with a solid detergent composition to form a use solution, wherein the
use solution comprises: from about 10 ppm to about 1000 ppm of at least
one alkali metal silicate; from about 5 ppm to about 200 ppm of at least
one saccharide or sugar alcohol; and contacting the substrate with the
use solution.

23. The method of claim 22, wherein the use solution further comprises:
from about 10 ppm to about 200 ppm of at least one polycarboxylic acid.

24. The method of claim 22, wherein the use solution further comprises
sodium carbonate and the sodium carbonate is present in a lesser amount
than the at least one alkali metal silicate.

25. The method of claim 22, wherein the at least one saccharide comprises
a mono-, di- or polysaccharide comprising three or more saccharide units.

26. The method of claim 22, wherein the at least one saccharide comprises
sucrose.

27. The method of claim 22, wherein the at least one sugar alcohol
comprises sorbitol.

28. A solid detergent composition comprising: from about 0.1 wt % to
about 70 wt % of at least one alkali metal silicate; from about 0.5 wt %
to about 10 wt % of at least one saccharide or sugar alcohol; from about
15 wt % to about 40 wt % sodium carbonate; and from about 10 wt % to
about 70 wt % water.

29. The composition of claim 28, wherein the at least one saccharide
comprises a mono-, di- or polysaccharide comprising three or more
saccharide units.

30. The composition of claim 28, wherein the at least one saccharide
comprises sucrose.

31. The composition of claim 28, wherein the at least one sugar alcohol
comprises sorbitol.

32. The solid detergent composition of claim 28, and further comprising:
from about 1 wt % to about 15 wt % of at least one polycarboxylic acid.

33. The composition of claim 32, wherein the polycarboxylic acid
comprises at least one maleic acid polymer, at least one acrylic acid
polymer or combinations thereof

34. The composition of claim 28 consisting essentially of the at least
one alkali metal silicate, the at least one saccharide or sugar alcohol,
sodium carbonate, water and optionally at least one polycarboxylic acid,
wherein if the composition is heated at a temperature of 120 degrees
Fahrenheit, the solid detergent composition is dimensionally stable and
has a growth exponent of less than 2%.

35. The composition of claim 28, wherein the composition is free of
phosphorous.

Description:

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit under 35 U.S.C. §119(e) to
U.S. Provisional Patent Application No. 61/434,668, filed on Jan. 20,
2011, entitled "Detergent Composition including a Saccharide," which is
incorporated herein by reference in its entirety.

[0003] The advent of solid block detergent compositions containing alkali
cleaning agents has revolutionized the manner in which detergents are
dispensed by commercial and institutional entities which routinely use
large quantities of cleaning solution. The solid block compositions are
generally formed by combining the alkali cleaning agent with one or more
solidification components in a liquid solution. The solidification
components interact with the alkali cleaning agent and cause the
composition to form a solid block with minimal if any energy input.

[0004] One challenge that arises when transporting and subsequently using
such solid block compositions is that swelling can occur particularly
when the solid block composition is subjected to higher temperature
conditions. The result is that the block composition may break apart,
damage the packaging in which it is stored and/or not fit properly into
dispensing machines. Various materials have been added to solid block
compositions to control swelling. However, increased regulation of
detergent compositions has created a need to identify compounds that help
control swelling while also having a low impact the environment.

SUMMARY

[0005] One embodiment is a solid detergent composition including at least
one alkali metal silicate, at least one saccharide or sugar alcohol and
water. Suitable saccharides include mono-, di- and polysaccharides
containing 3 or more saccharide units. Sucrose, fructose, inulin,
lactulose, maltose and combinations thereof, may be particularly
suitable.

[0006] Another embodiment is a solid detergent composition including from
about 0.1 wt % to about 70 wt % of at least one alkali metal silicate,
from about 0.5 wt % to about 10 wt % of at least one saccharide or sugar
alcohol, and from about 10 wt % to about 70 wt % water. A further
embodiment is a method of forming a solid detergent composition in which
at least one alkali metal silicate, at least one saccharide or sugar
alcohol and water are combined to form a mixture, and a solid detergent
composition is then formed from the mixture.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] FIG. 1 is a line graph illustrating percent swelling of embodiments
of the invention set forth in the Examples.

[0008]FIG. 2 is a line graph illustrating capsule growth of embodiments
of the invention set forth in the Examples

[0009] FIG. 3 is a line graph illustrating percent swelling of embodiments
of the invention set forth in the Examples.

[0010] FIG. 4 is a line graph illustrating capsule growth of embodiments
of the invention set forth in the Examples.

[0011] FIG. 5 is a line graph illustrating percent swelling of embodiments
of the invention set forth in the Examples.

[0012]FIG. 6 is a line graph illustrating capsule growth of embodiments
of the invention set forth in the Examples.

DETAILED DESCRIPTION

[0013] Embodiments of the present invention provide solid, dimensionally
stable, compositions including at least one alkali metal silicate
cleaning agent, water and at least one saccharide or sugar alcohol. Such
compositions may be particularly useful in cleaning applications where it
is desired to use a phosphate-free detergent. Such applications include,
but are not limited to: machine and manual warewashing, presoaks, laundry
and textile cleaning and destaining, carpet cleaning and destaining,
vehicle cleaning and care applications, surface cleaning and destaining,
kitchen and bath cleaning and destaining, floor cleaning and destaining,
cleaning in place operations, general purpose cleaning and destaining,
industrial or household cleaners, and pest control agents.

[0014] The solid detergent composition includes an effective amount of
alkali metal silicate sources to enhance cleaning of the desired
substrate and improve soil removal performance of the solid composition.
The composition may include the alkali metal silicate in an amount of
between about 0.1% by weight and 80% by weight, more particularly,
between about 10% by weight and about 60% by weight, and even more
particularly, between about 25% by weight and about 60% by weight.

[0015] An effective amount of one or more alkali metal silicate sources
may provide a use composition (i.e., an aqueous solution containing the
composition) having a pH of at least about 8. When the use composition
has a pH of between about 8 and about 10, it can be considered mildly
alkali, and when the pH is greater than about 12, the use composition can
be considered caustic.

[0016] Examples of suitable alkali metal silicates include lithium, sodium
and potassium silicate or metasilicate, as well as combinations of the
foregoing materials. The alkali metal silicate may be used to form the
composition without modification or may be combined with other raw
materials such as alkali metal hydroxide to form alkali metal
metasilicate prior to or in the process of making the solid composition.
Commercial sodium silicates are available in both powdered and liquid
forms. The powdered forms include both amorphous and crystalline powders
in either hydrated or anhydrous form. The aqueous liquids are available
with viscosities ranging from 0.5 to 600,000 centipoise at 20° C.
Potassium silicates are sold either as a glass or an aqueous liquid. The
synthetic lithium silicates typically are generally sold only as liquids.
The more common commercially available sodium silicates vary in
Na2O/SiO2 ratio from about 2:1 to about 1:4.

[0017] The solid forms of alkali metal silicates are generally classified
by particle-size range and Na2O/SiO2 ratio. The aqueous
solutions are identified by any combination of density/specific gravity,
alkali:silica ratio, and viscosity. Typically, the aqueous solutions are
differentiated on the basis of specific gravity and Na2O/SiO2
ratio. Concentrated solutions of highly alkali sodium silicates are quite
sticky or tacky. Conversely, concentrated solutions of highly siliceous
sodium silicate show little tack but are plastic enough to form into
balls which show a surprising elasticity.

[0018] The crystalline products which are readily available on a
commercial scale are the anhydrous and hydrated sodium metasilicates
(Na2SiO3, Na2SiO35H2O and SiO39H2O)
and the hydrated sodium sesquisilicates (Na2HSiO45H2O and
3Na2O2.SiO211H2O). The anhydrous sodium
sesquisilicate and the technically anhydrous orthosilicates are also
available but generally mixtures of caustic soda and sodium metasilicate.

[0019] The liquid products which are readily available on a commercial
scale include M2O:SiO2 ratios from about 1:1.5 to 1:3.8 for
sodium silicate and about 1:1.5 to about 1:2.5 for potassium silicate
with a water content from about 45 to about 75 wt % based upon the weight
of the silicate and the water.

[0020] A listing of commercially available alkali metal silicates are
provided in Tables 1-2 below. The physical properties of various
crystalline alkali silicates are provided in Table 3 below.

[0021] The solid composition may include between about 0.1% by weight and
about 25% by weight saccharide or sugar alcohol, more particularly,
between about 1.0% by weight and about 15% by weight saccharide or sugar
alcohol, even more particularly, between about 1.0% by weight and about
10% by weight saccharide or sugar alcohol, and even more particularly
from about 1.0% by weight to about 7.0% by weight saccharide or sugar
alcohol.

[0023] Examples of suitable inulin saccharides include, but are not
limited to, naturally-occurring and derivatized inulins. Derivatized
inulins are modified to be further substituted at a varying number of the
available hydroxyls, with alkyl, alkoxy, carboxy, and carboxyalkyl
moieties, for example. Examples of particularly suitable commercially
available carboxymethyl inulin-based polymers include, but are not
limited to: Dequest PB 11615, Dequest PB 11620 and Dequest PB 11625,
available from Solutia, Inc., St. Louis, Mo. DEQUEST PB 11625 is a 20%
solution of carboxymethyl inulin, sodium salt, having a MW>2000.

[0024] As discussed above, sugar alcohols may also be suitable. Examples
of suitable sugar alcohols include, but are not limited to, glycol,
glycerol, erythritol, threitol, arabitol, xylitol, ribitol, mannitol,
sorbitol, dulcitol, iditol, isomalt, malitol, polyglycitol, lactitol, and
other polyols. Examples of particularly suitable sugar alcohols include
but are not limited to sorbitol.

[0025] Water may be independently added to the composition or may be
provided in the composition as a result of its presence in an aqueous
material that is added to the detergent composition. For example,
materials added to the detergent composition may include water or may be
prepared in an aqueous premix. Typically, water is introduced into the
composition to provide a desired viscosity for processing prior to
solidification and to provide a desired rate of solidification. The water
may also be present as a processing aid and may be removed or become
water of hydration. The water may also be provided as deionized water or
as softened water.

[0026] The amount of water in the resulting solid detergent composition
will depend on whether the solid detergent composition is processed
through forming techniques or casting (solidification occurring within a
container) techniques. In general, when the components are processed by
forming techniques, the solid detergent composition may include a smaller
amount of water for solidification compared with the casting techniques.
When preparing the solid detergent composition by casting techniques,
water may be present in ranges of between about 5% and about 50% by
weight, particularly between about 10% and about 40% by weight, and more
particularly between about 20% and about 40% by weight.

[0027] The composition may optionally include at least about 0.5% by
weight of polycarboxylic acid polymer, copolymers and/or salts thereof,
more particularly, from about 1% by weight to about 25% by weight, even
more particularly, from about 3% by weight to about 15% by weight.
Examples of suitable polycarboxylic acid polymer include, but are not
limited to: polyacrylic acid polymers, polyacrylic acid polymers modified
by a fatty acid end group ("modified polyacrylic acid polymers"), and
polymaleic acid polymers. Examples of particularly suitable polyacrylic
acid polymers and modified polyacrylic acid polymers include those having
a molecular weight of between about 1,000 g/mol and about 100,000 g/mol.
Examples of more particularly suitable polymaleic acid polymers include
those having a molecular weight of between about 500 g/mol and about
5,000 g/mol.

[0028] An example of particularly suitable commercially available
polyacrylic acid polymer includes, but is not limited to, Acusol 445N,
available from Rohm & Haas LLC, Philadelphia, Pa. An example of
particularly suitable commercially available modified polyacrylic acid
polymer includes, but is not limited to, Alcosperse 325, available from
Alco Chemical, Chattanooga, Tenn. Examples of particularly suitable
commercially available polymaleic acid polymers include, but are not
limited to: Belclene 200, available from Houghton Chemical Corporation,
Boston, Mass. and Aquatreat AR-801, available from Alco Chemical,
Chattanooga, Tenn.

[0029] In one embodiment, at least two polycarboxylic acid polymers are
used. For example, the combination of at least one polyacrylic acid and
at least one polymaleic acid may be used to provide the composition with
suitable solidification properties. The polycarboxylic acid combinations
may further function as a corrosion inhibitor.

[0030] The solid detergent composition may be phosphorus-free and/or
nitrilotriacetic acid (NTA)-free to make the solid detergent composition
more environmentally beneficial. Phosphorus-free means a composition
having less than approximately 0.5 wt %, more particularly, less than
approximately 0.1 wt %, and even more particularly less than
approximately 0.01 wt % phosphorous based on the total weight of the
composition. NTA-free means a composition having less than approximately
0.5 wt %, less than approximately 0.1 wt %, and particularly less than
approximately 0.01 wt % NTA based on the total weight of the composition.
When the composition is NTA-free, it is also compatible with chlorine,
which functions as an anti-redeposition and stain-removal agent.

[0031] If the solid detergent composition swells after solidification,
various problems may occur, including but not limited to: decreased
density, integrity, appearance, and inability to dispense or package the
solid product. Generally, a solid product is considered to have
dimensional stability if the solid product has a growth exponent (i.e.,
percent swelling) of less than about 3% and particularly less than about
2%. Growth exponent refers to the percent growth of a product over a
period of time after solidification under normal transport/storage
conditions. Because normal transport/storage conditions for detergent
products may result in the solid detergent composition being subjected to
an elevated temperature, the growth exponent may be determined by
measuring one or more dimensions of the solid product prior to and after
heating to between 100° F. and 120° F. for several hours,
days or even weeks. The measured dimension depends on the shape of the
solid detergent composition. For tablet shaped compositions, both
diameter and height are generally measured. For capsule shaped
compositions, only diameter is generally measured.

[0032] Embodiments of the present invention including a saccharide or
sugar alcohol may have a growth exponent that is less than the growth
exponent of the same composition without a saccharide or sugar alcohol.
More particularly, of the present invention including a saccharide or
sugar alcohol may have a growth exponent that is less than about 3%, more
particularly, less than about 2% when subjected to elevated temperatures
of at least about 100° F., more particularly, about 120° F.
More particularly, the growth exponent may remain below 2% even after
heating at 120° F. for at least about three weeks.

Additional Functional Materials

[0033] The components of the detergent composition can be combined with
various functional components. In some embodiments, the alkali metal
silicate, saccharide or sugar alcohol and water make up a large amount,
or even substantially all of the total weight of the detergent
composition, for example, in embodiments having few or no additional
functional materials disposed therein. In these embodiments, the
component concentration ranges provided above for the detergent are
representative of the ranges of those same components in the detergent
composition. In other embodiments, the detergent composition consists
essentially of the alkali metal silicate, at least one saccharide or
sugar alcohol, water, at least one polycarboxylic acid, optionally sodium
carbonate, optionally at least one secondary alkali source and optionally
at least one surfactant.

[0034] The functional materials provide desired properties and
functionalities to the solid detergent composition. For the purpose of
this application, the term "functional materials" includes a material
that when dispersed or dissolved in a use and/or concentrate solution,
such as an aqueous solution, provides a beneficial property in a
particular use. Some particular examples of functional materials are
discussed in more detail below, although the particular materials
discussed are given by way of example only, and that a broad variety of
other functional materials may be used. Moreover, the components
discussed above may be multi-functional and may also provide several of
the functional benefits discussed below.

Secondary Alkali Source

[0035] The solid detergent composition can include one or more secondary
alkali sources. Examples of suitable secondary alkali sources of the
solid detergent composition include, but are not limited to alkali metal
carbonates and alkali metal hydroxides. Exemplary alkali metal carbonates
that can be used include, but are not limited to: sodium or potassium
carbonate, bicarbonate, sesquicarbonate, and mixtures thereof. Exemplary
alkali metal hydroxides that can be used include, but are not limited to:
sodium or potassium hydroxide. The alkali metal hydroxide may be added to
the composition in any form known in the art, including as solid beads,
dissolved in an aqueous solution, or a combination thereof. In some
embodiments, the detergent composition does not include a secondary
detergent source such as sodium carbonate. If included, the secondary
alkali source, for example sodium carbonate, may be present in
concentration of from 15-40 wt %. An exemplary detergent composition
including carbonate may have the following component and component
concentrations:

[0036] The solid detergent composition can include at least one cleaning
agent comprising a surfactant or surfactant system. A variety of
surfactants can be used in a solid detergent composition, including, but
not limited to: anionic, nonionic, cationic, and zwitterionic
surfactants. Surfactants are an optional component of the solid detergent
composition and can be excluded from the concentrate. Exemplary
surfactants that can be used are commercially available from a number of
sources. For a discussion of surfactants, see Kirk-Othmer, Encyclopedia
of Chemical Technology, Third Edition, volume 8, pages 900-912. When the
solid detergent composition includes a surfactant as a cleaning agent,
the cleaning agent is provided in an amount effective to provide a
desired level of cleaning The solid detergent composition, when provided
as a concentrate, can include the surfactant cleaning agent in a range of
about 0.05% to about 20% by weight, about 0.5% to about 15% by weight,
about 1% to about 15% by weight, about 1.5% to about 10% by weight, and
about 2% to about 8% by weight. Additional exemplary ranges of surfactant
in a concentrate include about 0.5% to about 8% by weight, and about 1%
to about 5% by weight.

[0038] Examples of nonionic surfactants useful in the solid detergent
composition include, but are not limited to, those having a polyalkylene
oxide polymer as a portion of the surfactant molecule. Such nonionic
surfactants include, but are not limited to: chlorine-, benzyl-, methyl-,
ethyl-, propyl-, butyl- and other like alkyl-capped polyethylene glycol
ethers of fatty alcohols; polyalkylene oxide free nonionics such as alkyl
polyglycosides; sorbitan and sucrose esters and their ethoxylates;
alkoxylated amines such as alkoxylated ethylene diamine; alcohol
alkoxylates such as alcohol ethoxylate propoxylates, alcohol
propoxylates, alcohol propoxylate ethoxylate propoxylates, alcohol
ethoxylate butoxylates; nonylphenol ethoxylate, polyoxyethylene glycol
ether; carboxylic acid esters such as glycerol esters, polyoxyethylene
esters, ethoxylated and glycol esters of fatty acids; carboxylic amides
such as diethanolamine condensates, monoalkanolamine condensates,
polyoxyethylene fatty acid amides; and polyalkylene oxide block
copolymers. An example of a commercially available ethylene
oxide/propylene oxide block copolymer includes, but is not limited to,
PLURONIC®, available from BASF Corporation, Florham Park, N.J. An
example of a commercially available silicone surfactant includes, but is
not limited to, ABIL® B8852, available from Goldschmidt Chemical
Corporation, Hopewell, Va.

[0039] Examples of cationic surfactants that can be used in the solid
detergent composition include, but are not limited to: amines such as
primary, secondary and tertiary monoamines with C18 alkyl or alkenyl
chains, ethoxylated alkylamines, alkoxylates of ethylenediamine,
imidazoles such as a 1-(2-hydroxyethyl)-2-imidazoline, a
2-alkyl-1-(2-hydroxyethyl)-2-imidazoline, and the like; and quaternary
ammonium salts, as for example, alkylquaternary ammonium chloride
surfactants such as n-alkyl(C12-C18)dimethylbenzyl ammonium
chloride, n-tetradecyldimethylbenzylammonium chloride monohydrate, and a
naphthylene-substituted quaternary ammonium chloride such as
dimethyl-1-naphthylmethylammonium chloride. The cationic surfactant can
be used to provide sanitizing properties.

[0040] Examples of zwitterionic surfactants that can be used in the solid
detergent composition include, but are not limited to: betaines,
imidazolines, and propionates.

[0041] Because the solid detergent composition is intended to be used in
an automatic dishwashing or warewashing machine, the surfactants
selected, if any surfactant is used, can be those that provide an
acceptable level of foaming when used inside a dishwashing or warewashing
machine. Solid detergent compositions for use in automatic dishwashing or
warewashing machines are generally considered to be low-foaming
compositions. Low foaming surfactants that provide the desired level of
detersive activity are advantageous in an environment such as a
dishwashing machine where the presence of large amounts of foaming can be
problematic. In addition to selecting low foaming surfactants, defoaming
agents can also be utilized to reduce the generation of foam.
Accordingly, surfactants that are considered low foaming surfactants can
be used. In addition, other surfactants can be used in conjunction with a
defoaming agent to control the level of foaming.

Builders or Water Conditioners

[0042] The solid detergent composition can include one or more building
agents, also called chelating or sequestering agents (e.g., builders),
including, but not limited to: condensed phosphates, alkali metal
carbonates, phosphonates, aminocarboxylic acids, and/or polyacrylates. In
general, a chelating agent is a molecule capable of coordinating (i.e.,
binding) the metal ions commonly found in natural water to prevent the
metal ions from interfering with the action of the other detersive
ingredients of a cleaning composition. Preferable levels of addition for
builders that can also be chelating or sequestering agents are between
about 0.1% to about 70% by weight, about 1% to about 60% by weight, or
about 1.5% to about 50% by weight. If the solid detergent is provided as
a concentrate, the concentrate can include between approximately 1% to
approximately 60% by weight, between approximately 3% to approximately
50% by weight, and between approximately 6% to approximately 45% by
weight of the builders. Additional ranges of the builders include between
approximately 3% to approximately 20% by weight, between approximately 6%
to approximately 15% by weight, between approximately 25% to
approximately 50% by weight, and between approximately 35% to
approximately 45% by weight.

[0043] Examples of condensed phosphates include, but are not limited to:
sodium and potassium orthophosphate, sodium and potassium pyrophosphate,
sodium tripolyphosphate, and sodium hexametaphosphate. A condensed
phosphate may also assist, to a limited extent, in solidification of the
solid detergent composition by fixing the free water present in the
composition as water of hydration.

[0044] Examples of phosphonates included, but are not limited to:
2-phosphonobutane-1,2,4-tricarboxylic acid (PBTC), 1-hydroxyethane-1,
1-diphosphonic acid, CH2C(OH)[PO(OH)2]2;
aminotri(methylenephosphonic acid), N[CH2 PO(OH)2]3;
aminotri(methylenephosphonate), sodium salt (ATMP), N[CH2
PO(ONa)2]3; 2-hydroxyethyliminobis(methylenephosphonic acid),
HOCH2CH2N[CH2PO(OH)2]2;
diethylenetriaminepenta(methylenephosphonic acid),
(HO)2POCH2N[CH2CH2N[CH2PO(OH)2]2]2; diethylenetriaminepenta(methylenephosphonate), sodium salt (DTPMP),
C9H(28-x)N3NaxO15P5 (x=7);
hexamethylenediamine(tetramethylenephosphonate), potassium salt,
C10H.sub.(28-x)N2KxO12P4 (x=6);
bis(hexamethylene)triamine(pentamethylenephosphonic acid),
(HO2)POCH2N[(CH2)2N[CH2PO(OH)2]2]2; and phosphorus acid, H3PO3. A preferred phosphonate
combination is ATMP and DTPMP. A neutralized or alkali phosphonate, or a
combination of the phosphonate with an alkali source prior to being added
into the mixture such that there is little or no heat or gas generated by
a neutralization reaction when the phosphonate is added is preferred. In
one embodiment, however, the detergent composition if free of
phosphorous.

[0046] Water conditioning polymers can be used as non-phosphorus
containing builders. Exemplary water conditioning polymers include, but
are not limited to: polycarboxylates. Exemplary polycarboxylates that can
be used as builders and/or water conditioning polymers include, but are
not limited to: those having pendant carboxylate (--CO2.sup.-)
groups such as polyacrylic acid, maleic acid, maleic/olefin copolymer,
sulfonated copolymer or terpolymer, acrylic/maleic copolymer,
polymethacrylic acid, acrylic acid-methacrylic acid copolymers,
hydrolyzed polyacrylamide, hydrolyzed polymethacrylamide, hydrolyzed
polyamide-methacrylamide copolymers, hydrolyzed polyacrylonitrile,
hydrolyzed polymethacrylonitrile, and hydrolyzed
acrylonitrile-methacrylonitrile copolymers. Other suitable water
conditioning polymers include starch, sugar or polyols comprising
carboxylic acid or ester functional groups. Exemplary carboxylic acids
include but are not limited to maleic, acrylic, methacrylic and itaconic
acid or salts thereof. Exemplary ester functional groups include aryl,
cyclic, aromatic and C1-C10 linear, branched or substituted
esters. For a further discussion of chelating agents/sequestrants, see
Kirk-Othmer, Encyclopedia of Chemical Technology, Third Edition, volume
5, pages 339-366 and volume 23, pages 319-320, the disclosure of which is
incorporated by reference herein. These materials may also be used at
substoichiometric levels to function as crystal modifiers

Hardening Agents

[0047] The solid detergent compositions can also include a hardening agent
in addition to, or in the form of, the builder. A hardening agent is a
compound or system of compounds, organic or inorganic, which
significantly contributes to the uniform solidification of the
composition. Preferably, the hardening agents are compatible with the
cleaning agent and other active ingredients of the composition and are
capable of providing an effective amount of hardness and/or aqueous
solubility to the processed composition. The hardening agents should also
be capable of forming a homogeneous matrix with the cleaning agent and
other ingredients when mixed and solidified to provide a uniform
dissolution of the cleaning agent from the solid detergent composition
during use.

[0048] The amount of hardening agent included in the solid detergent
composition will vary according to factors including, but not limited to:
the type of solid detergent composition being prepared, the ingredients
of the solid detergent composition, the intended use of the composition,
the quantity of dispensing solution applied to the solid composition over
time during use, the temperature of the dispensing solution, the hardness
of the dispensing solution, the physical size of the solid detergent
composition, the concentration of the other ingredients, and the
concentration of the cleaning agent in the composition. It is preferred
that the amount of the hardening agent included in the solid detergent
composition is effective to combine with the cleaning agent and other
ingredients of the composition to form a homogeneous mixture under
continuous mixing conditions and a temperature at or below the melting
temperature of the hardening agent.

[0049] It is also preferred that the hardening agent form a matrix with
the cleaning agent and other ingredients which will harden to a solid
form under ambient temperatures of approximately 30° C. to
approximately 50° C., particularly approximately 35° C. to
approximately 45° C., after mixing ceases and the mixture is
dispensed from the mixing system, within approximately 1 minute to
approximately 3 hours, particularly approximately 2 minutes to
approximately 2 hours, and particularly approximately 5 minutes to
approximately 1 hour. A minimal amount of heat from an external source
may be applied to the mixture to facilitate processing of the mixture. It
is preferred that the amount of the hardening agent included in the solid
detergent composition is effective to provide a desired hardness and
desired rate of controlled solubility of the processed composition when
placed in an aqueous medium to achieve a desired rate of dispensing the
cleaning agent from the solidified composition during use.

[0050] The hardening agent may be an organic or an inorganic hardening
agent. A preferred organic hardening agent is a polyethylene glycol (PEG)
compound. The solidification rate of solid detergent compositions
comprising a polyethylene glycol hardening agent will vary, at least in
part, according to the amount and the molecular weight of the
polyethylene glycol added to the composition. Examples of suitable
polyethylene glycols include, but are not limited to: solid polyethylene
glycols of the general formula H(OCH2CH2)nOH, where n is
greater than 15, particularly approximately 30 to approximately 1700.
Typically, the polyethylene glycol is a solid in the form of a
free-flowing powder or flakes, having a molecular weight of approximately
1,000 to approximately 100,000, particularly having a molecular weight of
at least approximately 1,450 to approximately 20,000, more particularly
between approximately 1,450 to approximately 8,000. The polyethylene
glycol is present at a concentration of from approximately 1% to 75% by
weight and particularly approximately 3% to approximately 15% by weight.
Suitable polyethylene glycol compounds include, but are not limited to:
PEG 4000, PEG 1450, and PEG 8000 among others, with PEG 4000 and PEG 8000
being most preferred. An example of a commercially available solid
polyethylene glycol includes, but is not limited to: CARBOWAX, available
from Union Carbide Corporation, Houston, Tex.

[0051] Preferred inorganic hardening agents are hydratable inorganic
salts, including, but not limited to: sulfates and bicarbonates. The
inorganic hardening agents are present at concentrations of up to
approximately 50% by weight, particularly approximately 5% to
approximately 25% by weight, and more particularly approximately 5% to
approximately 15% by weight. In one embodiment, however, the solid
composition if free of sulfates and carbonates including soda ash.

[0052] Urea particles can also be employed as hardeners in the solid
detergent compositions. The solidification rate of the compositions will
vary, at least in part, to factors including, but not limited to: the
amount, the particle size, and the shape of the urea added to the
composition. For example, a particulate form of urea can be combined with
a cleaning agent and other ingredients, and preferably a minor but
effective amount of water. The amount and particle size of the urea is
effective to combine with the cleaning agent and other ingredients to
form a homogeneous mixture without the application of heat from an
external source to melt the urea and other ingredients to a molten stage.
It is preferred that the amount of urea included in the solid detergent
composition is effective to provide a desired hardness and desired rate
of solubility of the composition when placed in an aqueous medium to
achieve a desired rate of dispensing the cleaning agent from the
solidified composition during use. In some embodiments, the composition
includes between approximately 5% to approximately 90% by weight urea,
particularly between approximately 8% and approximately 40% by weight
urea, and more particularly between approximately 10% and approximately
30% by weight urea.

[0053] The urea may be in the form of prilled beads or powder. Prilled
urea is generally available from commercial sources as a mixture of
particle sizes ranging from about 8-15 U.S. mesh, as for example, from
Arcadian Sohio Company, Nitrogen Chemicals Division. A prilled form of
urea is preferably milled to reduce the particle size to about 50 U.S.
mesh to about 125 U.S. mesh, particularly about 75-100 U.S. mesh,
preferably using a wet mill such as a single or twin-screw extruder, a
Teledyne mixer, a Ross emulsifier, and the like.

Bleaching Agents

[0054] Bleaching agents suitable for use in the solid detergent
composition for lightening or whitening a substrate include bleaching
compounds capable of liberating an active halogen species, such as
Cl2, Br2, --OCl.sup.- and/or --OBr.sup.-, under conditions
typically encountered during the cleansing process. Suitable bleaching
agents for use in the solid detergent compositions include, but are not
limited to: chlorine-containing compounds such as chlorines,
hypochlorites, or chloramines. Exemplary halogen-releasing compounds
include, but are not limited to: the alkali metal dichloroisocyanurates,
chlorinated trisodium phosphate, the alkali metal hypochlorites,
monochloramine, and dichloramine. Encapsulated chlorine sources may also
be used to enhance the stability of the chlorine source in the
composition (see, for example, U.S. Pat. Nos. 4,618,914 and 4,830,773,
the disclosure of which is incorporated by reference herein). A bleaching
agent may also be a peroxygen or active oxygen source such as hydrogen
peroxide, perborates, sodium carbonate peroxyhydrate, potassium
permonosulfate, and sodium perborate mono and tetrahydrate, with and
without activators such as tetraacetylethylene diamine. When the
concentrate includes a bleaching agent, it can be included in an amount
of between approximately 0.1% and approximately 60% by weight, between
approximately 1% and approximately 20% by weight, between approximately
3% and approximately 8% by weight, and between approximately 3% and
approximately 6% by weight.

Fillers

[0055] The solid detergent composition can include an effective amount of
detergent fillers which do not perform as a cleaning agent per se, but
cooperates with the cleaning agent to enhance the overall cleaning
capacity of the composition. Examples of detergent fillers suitable for
use in the present cleaning compositions include, but are not limited to:
sodium sulfate and sodium chloride. When the concentrate includes a
detergent filler, it can be included in an amount up to approximately 50%
by weight, between approximately 1% and approximately 30% by weight, or
between approximately 1.5% and approximately 25% by weight.

Defoaming Agents

[0056] A defoaming agent for reducing the stability of foam may also be
included in the warewashing composition. Examples of defoaming agents
include, but are not limited to: ethylene oxide/propylene block
copolymers such as those available under the name Pluronic N-3; silicone
compounds such as silica dispersed in polydimethylsiloxane,
polydimethylsiloxane, and functionalized polydimethylsiloxane such as
those available under the name Abil B9952; fatty amides, hydrocarbon
waxes, fatty acids, fatty esters, fatty alcohols, fatty acid soaps,
ethoxylates, mineral oils, polyethylene glycol esters, and alkyl
phosphate esters such as monostearyl phosphate. A discussion of defoaming
agents may be found, for example, in U.S. Pat. No. 3,048,548 to Martin et
al., U.S. Pat. No. 3,334,147 to Brunelle et al., and U.S. Pat. No.
3,442,242 to Rue et al., the disclosures of which are incorporated herein
by reference. When the concentrate includes a defoaming agent, the
defoaming agent can be provided in an amount of between approximately
0.0001% and approximately 10% by weight, between approximately 0.001% and
approximately 5% by weight, or between approximately 0.01% and
approximately 1.0% by weight.

Anti-Redeposition Agents

[0057] The solid detergent composition can include an anti-redeposition
agent for facilitating sustained suspension of soils in a cleaning
solution and preventing the removed soils from being redeposited onto the
substrate being cleaned. Examples of suitable anti-redeposition agents
include, but are not limited to: polyacrylates, styrene maleic anhydride
copolymers, cellulosic derivatives such as hydroxyethyl cellulose,
hydroxypropyl cellulose and carboxymethyl cellulose. When the concentrate
includes an anti-redeposition agent, the anti-redeposition agent can be
included in an amount of between approximately 0.5% and approximately 10%
by weight, and between approximately 1% and approximately 5% by weight.

Stabilizing Agents

[0058] The solid detergent composition may also include stabilizing
agents. Examples of suitable stabilizing agents include, but are not
limited to: borate, calcium/magnesium ions, propylene glycol, and
mixtures thereof. The concentrate need not include a stabilizing agent,
but when the concentrate includes a stabilizing agent, it can be included
in an amount that provides the desired level of stability of the
concentrate. Exemplary ranges of the stabilizing agent include up to
approximately 20% by weight, between approximately 0.5% and approximately
15% by weight, and between approximately 2% and approximately 10% by
weight.

Dispersants

[0059] The solid detergent composition may also include dispersants.
Examples of suitable dispersants that can be used in the solid detergent
composition include, but are not limited to: maleic acid/olefin
copolymers, polyacrylic acid, and mixtures thereof. The concentrate need
not include a dispersant, but when a dispersant is included it can be
included in an amount that provides the desired dispersant properties.
Exemplary ranges of the dispersant in the concentrate can be up to
approximately 20% by weight, between approximately 0.5% and approximately
15% by weight, and between approximately 2% and approximately 9% by
weight.

Enzymes

[0060] Enzymes that can be included in the solid detergent composition
include those enzymes that aid in the removal of starch and/or protein
stains. Exemplary types of enzymes include, but are not limited to:
proteases, alpha-amylases, and mixtures thereof. Exemplary proteases that
can be used include, but are not limited to: those derived from Bacillus
licheniformix, Bacillus lenus, Bacillus alcalophilus, and Bacillus
amyloliquefacins. Exemplary alpha-amylases include Bacillus subtilis,
Bacillus amyloliquefaceins and Bacillus licheniformis. The concentrate
need not include an enzyme, but when the concentrate includes an enzyme,
it can be included in an amount that provides the desired enzymatic
activity when the solid detergent composition is provided as a use
composition. Exemplary ranges of the enzyme in the concentrate include up
to approximately 15% by weight, between approximately 0.5% to
approximately 10% by weight, and between approximately 1% to
approximately 5% by weight.

Glass and Metal Corrosion Inhibitors

[0061] The solid detergent composition can include a metal corrosion
inhibitor in an amount up to approximately 50% by weight, between
approximately 1% and approximately 40% by weight, or between
approximately 3% and approximately 30% by weight. The corrosion inhibitor
is included in the solid detergent composition in an amount sufficient to
provide a use solution that exhibits a rate of corrosion and/or etching
of glass that is less than the rate of corrosion and/or etching of glass
for an otherwise identical use solution except for the absence of the
corrosion inhibitor. It is expected that the use solution will include at
least approximately 6 parts per million (ppm) of the corrosion inhibitor
to provide desired corrosion inhibition properties. It is expected that
larger amounts of corrosion inhibitor can be used in the use solution
without deleterious effects. It is expected that at a certain point, the
additive effect of increased corrosion and/or etching resistance with
increasing corrosion inhibitor concentration will be lost, and additional
corrosion inhibitor will simply increase the cost of using the solid
detergent composition. The use solution can include between approximately
6 ppm and approximately 300 ppm of the corrosion inhibitor, and between
approximately 20 ppm and approximately 200 ppm of the corrosion
inhibitor. Examples of suitable corrosion inhibitors include, but are not
limited to: a combination of a source of aluminum ion and a source of
zinc ion, as well as an alkali metal silicate or hydrate thereof.

[0062] The corrosion inhibitor can refer to the combination of a source of
aluminum ion and a source of zinc ion. The source of aluminum ion and the
source of zinc ion provide aluminum ion and zinc ion, respectively, when
the solid detergent composition is provided in the form of a use
solution. The amount of the corrosion inhibitor is calculated based upon
the combined amount of the source of aluminum ion and the source of zinc
ion. Anything that provides an aluminum ion in a use solution can be
referred to as a source of aluminum ion, and anything that provides a
zinc ion when provided in a use solution can be referred to as a source
of zinc ion. It is not necessary for the source of aluminum ion and/or
the source of zinc ion to react to form the aluminum ion and/or the zinc
ion. Aluminum ions can be considered a source of aluminum ion, and zinc
ions can be considered a source of zinc ion. The source of aluminum ion
and the source of zinc ion can be provided as organic salts, inorganic
salts, and mixtures thereof. Exemplary sources of aluminum ion include,
but are not limited to: aluminum salts such as sodium aluminate, aluminum
bromide, aluminum chlorate, aluminum chloride, aluminum iodide, aluminum
nitrate, aluminum sulfate, aluminum acetate, aluminum formate, aluminum
tartrate, aluminum lactate, aluminum oleate, aluminum bromate, aluminum
borate, aluminum potassium sulfate, aluminum zinc sulfate, and aluminum
phosphate. Exemplary sources of zinc ion include, but are not limited to:
zinc salts such as zinc chloride, zinc sulfate, zinc nitrate, zinc
iodide, zinc thiocyanate, zinc fluorosilicate, zinc dichromate, zinc
chlorate, sodium zincate, zinc gluconate, zinc acetate, zinc benzoate,
zinc citrate, zinc lactate, zinc formate, zinc bromate, zinc bromide,
zinc fluoride, zinc fluorosilicate, and zinc salicylate.

[0063] The applicants discovered that by controlling the ratio of the
aluminum ion to the zinc ion in the use solution, it is possible to
provide reduced corrosion and/or etching of glassware and ceramics
compared with the use of either component alone. That is, the combination
of the aluminum ion and the zinc ion can provide a synergy in the
reduction of corrosion and/or etching. The ratio of the source of
aluminum ion to the source of zinc ion can be controlled to provide a
synergistic effect. In general, the weight ratio of aluminum ion to zinc
ion in the use solution can be between at least approximately 6:1, can be
less than approximately 1:20, and can be between approximately 2:1 and
approximately 1:15.

Fragrances and Dyes

[0064] Various dyes, odorants including perfumes, and other aesthetic
enhancing agents can also be included in the composition. Suitable dyes
that may be included to alter the appearance of the composition, include,
but are not limited to: Direct Blue 86, available from Mac Dye-Chem
Industries, Ahmedabad, India; Fastusol Blue, available from Mobay
Chemical Corporation, Pittsburgh, Pa.; Acid Orange 7, available from
American Cyanamid Company, Wayne, N.J.; Basic Violet 10 and Sandolan
Blue/Acid Blue 182, available from Sandoz, Princeton, N.J.; Acid Yellow
23, available from Chemos GmbH, Regenstauf, Germany; Acid Yellow 17,
available from Sigma Chemical, St. Louis, Mo.; Sap Green and Metanil
Yellow, available from Keyston Analine and Chemical, Chicago, Ill; Acid
Blue 9, available from Emerald Hilton Davis, LLC, Cincinnati, Ohio; Hisol
Fast Red and Fluorescein, available from Capitol Color and Chemical
Company, Newark, N.J.; and Acid Green 25, Ciba Specialty Chemicals
Corporation, Greenboro, N.C.

[0065] Fragrances or perfumes that may be included in the compositions
include, but are not limited to: terpenoids such as citronellol,
aldehydes such as amyl cinnamaldehyde, a jasmine such as C1S-jasmine or
jasmal, and vanillin.

Thickeners

[0066] The solid detergent compositions can include a rheology modifier or
a thickener. The rheology modifier may provide the following functions:
increasing the viscosity of the compositions; increasing the particle
size of liquid use solutions when dispensed through a spray nozzle;
providing the use solutions with vertical cling to surfaces; providing
particle suspension within the use solutions; or reducing the evaporation
rate of the use solutions.

[0067] The rheology modifier may provide a use composition that is pseudo
plastic, in other words the use composition or material when left
undisturbed (in a shear mode), retains a high viscosity. However, when
sheared, the viscosity of the material is substantially but reversibly
reduced. After the shear action is removed, the viscosity returns. These
properties permit the application of the material through a spray head.
When sprayed through a nozzle, the material undergoes shear as it is
drawn up a feed tube into a spray head under the influence of pressure
and is sheared by the action of a pump in a pump action sprayer. In
either case, the viscosity can drop to a point such that substantial
quantities of the material can be applied using the spray devices used to
apply the material to a soiled surface. However, once the material comes
to rest on a soiled surface, the materials can regain high viscosity to
ensure that the material remains in place on the soil. Preferably, the
material can be applied to a surface resulting in a substantial coating
of the material that provides the cleaning components in sufficient
concentration to result in lifting and removal of the hardened or
baked-on soil. While in contact with the soil on vertical or inclined
surfaces, the thickeners in conjunction with the other components of the
cleaner minimize dripping, sagging, slumping or other movement of the
material under the effects of gravity. The material should be formulated
such that the viscosity of the material is adequate to maintain contact
between substantial quantities of the film of the material with the soil
for at least a minute, particularly five minutes or more.

[0068] Examples of suitable thickeners or rheology modifiers are polymeric
thickeners including, but not limited to: polymers or natural polymers or
gums derived from plant or animal sources. Such materials may be
polysaccharides such as large polysaccharide molecules having substantial
thickening capacity. Thickeners or rheology modifiers also include clays.

[0069] A substantially soluble polymeric thickener can be used to provide
increased viscosity or increased conductivity to the use compositions.
Examples of polymeric thickeners for the aqueous compositions of the
invention include, but are not limited to: carboxylated vinyl polymers
such as polyacrylic acids and sodium salts thereof, ethoxylated
cellulose, polyacrylamide thickeners, cross-linked, xanthan compositions,
sodium alginate and algin products, hydroxypropyl cellulose, hydroxyethyl
cellulose, and other similar aqueous thickeners that have some
substantial proportion of water solubility. Examples of suitable
commercially available thickeners include, but are not limited to:
Acusol, available from Rohm & Haas Company, Philadelphia, Pa.; and
Carbopol, available from B.F. Goodrich, Charlotte, N.C.

[0070] Examples of suitable polymeric thickeners include, but not limited
to: polysaccharides. An example of a suitable commercially available
polysaccharide includes, but is not limited to, Diutan, available from
Kelco Division of Merck, San Diego, Calif. Thickeners for use in the
solid detergent compositions further include polyvinyl alcohol
thickeners, such as, fully hydrolyzed (greater than 98.5 mol acetate
replaced with the --OH function).

[0071] An example of a particularly suitable polysaccharide includes, but
is not limited to, xanthans. Such xanthan polymers are preferred due to
their high water solubility, and great thickening power. Xanthan is an
extracellular polysaccharide of xanthomonas campestras. Xanthan may be
made by fermentation based on corn sugar or other corn sweetener
by-products. Xanthan comprises a poly beta-(1-4)-D-Glucopyranosyl
backbone chain, similar to that found in cellulose. Aqueous dispersions
of xanthan gum and its derivatives exhibit novel and remarkable
rheological properties. Low concentrations of the gum have relatively
high viscosities which permit it to be used economically. Xanthan gum
solutions exhibit high pseudo plasticity, i.e. over a wide range of
concentrations, rapid shear thinning occurs that is generally understood
to be instantaneously reversible. Non-sheared materials have viscosities
that appear to be independent of the pH and independent of temperature
over wide ranges. Preferred xanthan materials include crosslinked xanthan
materials. Xanthan polymers can be crosslinked with a variety of known
covalent reacting crosslinking agents reactive with the hydroxyl
functionality of large polysaccharide molecules and can also be
crosslinked using divalent, trivalent or polyvalent metal ions. Such
crosslinked xanthan gels are disclosed in U.S. Pat. No. 4,782,901, which
is herein incorporated by reference. Suitable crosslinking agents for
xanthan materials include, but are not limited to: metal cations such as
Al+3, Fe+3, Sb+3, Zr+4 and other transition metals. Examples of suitable
commercially available xanthans include, but are not limited to:
KELTROL®, KELZAN® AR, KELZAN® D35, KELZAN® S, KELZAN®
XZ, available from Kelco Division of Merck, San Diego, Calif. Known
organic crosslinking agents can also be used. A preferred crosslinked
xanthan is KELZAN® AR, which provides a pseudo plastic use solution
that can produce large particle size mist or aerosol when sprayed.

Methods of Manufacture

[0072] In general, a solid detergent composition of the present invention
can be created by combining the alkali metal silicate, polycarboxylate
polymer, saccharide or sugar alcohol, water, and any additional
functional components and allowing the components to interact and
solidify.

[0073] The alkali metal silicate, and additional functional components
harden into solid form due to the chemical reaction of the metal silicate
with the water. The solidification process may last from a few minutes to
about six hours, depending on factors including, but not limited to: the
size of the formed or cast composition, the ingredients of the
composition, and the temperature of the composition.

[0074] The solid detergent compositions may be formed using a batch or
continuous mixing system. In an exemplary embodiment, a single- or
twin-screw extruder is used to combine and mix one or more cleaning
agents at high shear to form a homogeneous mixture. In some embodiments,
the processing temperature is at or below the melting temperature of the
components. The processed mixture may be dispensed from the mixer by
forming, casting or other suitable means, whereupon the detergent
composition hardens to a solid form. The structure of the matrix may be
characterized according to its hardness, melting point, material
distribution, crystal structure, and other like properties according to
known methods in the art. Generally, a solid detergent composition
processed according to the method of the invention is substantially
homogeneous with regard to the distribution of ingredients throughout its
mass and is dimensionally stable.

[0075] In an extrusion process, the liquid and solid components are
introduced into final mixing system and are continuously mixed until the
components form a substantially homogeneous semi-solid mixture in which
the components are distributed throughout its mass. The mixture is then
discharged from the mixing system into, or through, a die or other
shaping means. The product is then packaged. In an exemplary embodiment,
the formed composition begins to harden to a solid form in between
approximately 1 minute and approximately 3 hours. Particularly, the
formed composition begins to harden to a solid form in between
approximately 1 minute and approximately 2 hours. More particularly, the
formed composition begins to harden to a solid form in between
approximately 1 minute and approximately 20 minutes.

[0076] In a casting process, the liquid and solid components are
introduced into the final mixing system and are continuously mixed until
the components form a substantially homogeneous liquid mixture in which
the components are distributed throughout its mass. In an exemplary
embodiment, the components are mixed in the mixing system for at least
approximately 60 seconds. Once the mixing is complete, the product is
transferred to a packaging container where solidification takes place. In
an exemplary embodiment, the cast composition begins to harden to a solid
form in between approximately 1 minute and approximately 3 hours.
Particularly, the cast composition begins to harden to a solid form in
between approximately 1 minute and approximately 2 hours. More
particularly, the cast composition begins to harden to a solid form in
between approximately 1 minute and approximately 20 minutes.

[0077] By the term "solid", it is meant that the hardened composition will
not flow and will substantially retain its shape under moderate stress or
pressure or mere gravity. The degree of hardness of the solid cast
composition may range from that of a fused solid product which is
relatively dense and hard, for example, like concrete, to a consistency
characterized as being a hardened paste. In addition, the term "solid"
refers to the state of the detergent composition under the expected
conditions of storage and use of the solid detergent composition. In
general, it is expected that the detergent composition will remain in
solid form when exposed to temperatures of up to approximately
100° F. and particularly up to approximately 120° F.

[0078] The resulting solid detergent composition may take forms including,
but not limited to: a cast solid product; an extruded, molded or formed
solid pellet, block, tablet, powder, granule, flake; or the formed solid
can thereafter be ground or formed into a powder, granule, or flake. In
an exemplary embodiment, extruded pellet materials formed by the
solidification matrix have a weight of between approximately 50 grams and
approximately 250 grams, extruded solids formed by the composition have a
weight of approximately 100 grams or greater, and solid block detergents
formed by the composition have a mass of between approximately 1 and
approximately 10 kilograms. The solid compositions provide for a
stabilized source of functional materials. In some embodiments, the solid
composition may be dissolved, for example, in an aqueous or other medium,
to create a concentrated and/or use solution. The solution may be
directed to a storage reservoir for later use and/or dilution, or may be
applied directly to a point of use.

[0079] In certain embodiments, the solid detergent composition is provided
in the form of a unit dose. A unit dose refers to a solid detergent
composition unit sized so that the entire unit is used during a single
washing cycle. When the solid detergent composition is provided as a unit
dose, it is typically provided as a cast solid, an extruded pellet, or a
tablet having a size of between approximately 1 gram and approximately 50
grams.

[0080] In other embodiments, the solid detergent composition is provided
in the form of a multiple-use solid, such as a block or a plurality of
pellets, and can be repeatedly used to generate aqueous detergent
compositions for multiple washing cycles. In certain embodiments, the
solid detergent composition is provided as a cast solid, an extruded
block, or a tablet having a mass of between approximately 5 grams and
approximately 10 kilograms. In certain embodiments, a multiple-use form
of the solid detergent composition has a mass between approximately 1
kilogram and approximately 10 kilograms. In further embodiments, a
multiple-use form of the solid detergent composition has a mass of
between approximately 5 kilograms and about approximately 8 kilograms. In
other embodiments, a multiple-use form of the solid detergent composition
has a mass of between about approximately 5 grams and approximately 1
kilogram, or between approximately 5 grams and approximately 500 grams.

[0081] Although the detergent composition is discussed as being formed
into a solid product, the detergent composition may also be provided in
the form of a paste. When the concentrate is provided in the form of a
paste, enough water is added to the detergent composition such that
complete solidification of the detergent composition is precluded. In
addition, dispersants and other components may be incorporated into the
detergent composition in order to maintain a desired distribution of
components.

Method of Using

[0082] The detergent composition is a concentrate solid which can be
diluted with water, known as dilution water, to form a concentrate
solution or a use solution. In general, a concentrate refers to a
composition that is intended to be diluted with water to provide a use
solution; a use solution is dispersed or used without further dilution.
The use solution can be used to clean substrates such as during
warewashing.

[0083] In one example, the solid detergent composition is diluted such
that the use solution has sufficient detersivity. The typical dilution
factor is between approximately 1 and approximately 10,000 but will
depend on factors including water hardness, the amount of soil to be
removed and the like. In one embodiment, the solid detergent composition
is diluted at a ratio of between about 1:10 and about 1:1000 concentrate
to water. Particularly, the solid detergent composition is diluted at a
ratio of between about 1:100 and about 1:5000 concentrate to water. More
particularly, the solid detergent composition is diluted at a ratio of
between about 1:250 and 1:2000 concentrate to water.

[0084] Suitable concentration ranges for the use solution include between
about 10 ppm and about 1000 ppm of at least one alkali metal silicate,
between about 5 ppm and about 200 ppm of at least one saccharide or sugar
alcohol, and between about 10% and about 70% by weight water. When a
polysaccharide is present, a suitable concentration range for at least
one polysaccharide is between about 10 ppm and about 200 ppm. When sodium
carbonate is present, a suitable concentration range for sodium carbonate
is between about 1 ppm and about 1000 ppm.

[0085] The solid detergent concentrate can contain an effective
concentration of the at least one alkali metal silicate and optionally
sodium carbonate so that use composition has a pH of at least about 9.

EXAMPLES

[0086] The present invention is more particularly described in the
following examples that are intended as illustrations only, since
numerous modifications and variations within the scope of the present
invention will be apparent to those skilled in the art. Unless otherwise
noted, all parts, percentages, and ratios reported in the following
examples are on a weight basis, and all reagents used in the examples
were obtained, or are available, from the chemical suppliers described
below, or may be synthesized by conventional techniques.

[0096] The raw materials identified for each of Examples 1-6 in Table 5
below were combined and mixed. Example 1 was a control containing no
saccharide. Each of the remaining Examples 2-6 included equal weight
percentages of the identified saccharide.

[0097] Once thoroughly mixed, each example was then poured into a 16 oz
cylindrical high density polyethylene container with a line drawn around
the circumference of the container about 1.75 inches from the container
bottom. The mixtures were allowed to harden into capsules in the
container. Once hardened, three diameter measurements were taken via
caliper for each of the six containers corresponding to Experiments 1-6
and then separately averaged to determine an initial capsule diameter.

[0098] The containers were then placed in an oven at 122° F. for 5
weeks with additional diameter measurements taken once a week to
determine the average increase in swelling capsule growth of each
Example. FIGS. 1 and 2 are line graphs showing the results, which
indicate that Examples 2-6 containing equal weight percentages of various
saccharides exhibited reduced swelling and diameter increase compared to
the control, which included no saccharide. In particular, Examples 2-6
experienced less than two percent swelling over the five week test
period.

Examples 7-10

[0099] Examples 7-10 set forth in Table 6 below were prepared in the same
manner as Examples 1-6 except that equal mole amounts of the saccharides
were used.

[0100] The containers containing the capsules were then heated and
measured as described with respect to Example 1-6. FIGS. 3 and 4 are line
graphs showing the results, which indicate that Examples 7-10 containing
equal mole amounts of various saccharides exhibited reduced diameter
increase and swelling compared to control Example 1, which included no
saccharide. In particular, Examples 7-10 experienced less than two
percent swelling over the five week test period.

Examples 11-13

[0101] Examples 11-13 set forth in Table 7 below were prepared in the same
manner as Examples 1-6 except Examples 11-13 also included sodium
carbonate. Example 11 was a control which did not contain a saccharide,
and Example 12 included a saccharide, and Example 13 contained a sugar
alcohol.

[0102] The containers containing the capsules were then heated and
measured as described with respect to Examples 1-6. FIGS. 5 and 6 are
line graphs showing the results, which indicate that Examples 12 and 13,
which contained a saccharide, exhibited reduced diameter increase and
swelling compared to control Example 11. In particular, Examples 12 and
13 experienced about 0.5% or less swelling over the five week storage
period.

[0103] Although the present invention has been described with reference to
preferred embodiments, workers skilled in the art will recognize that
changes may be made in form and detail without departing from the spirit
and scope of the invention.